Unit 4: Production system
4.1 Production system
 A production system is a process that produces
goods or services.
 It involves the conversion of raw materials into
finished products through a series of operations or
activities.
 The production system can be designed in various
ways depending on the nature of the product,
volume of production, resources available, and other
factors.
 The main goal of a production system is to produce
high-quality products efficiently and effectively while
minimizing costs and maximizing profits.
4.2 Design of production system
The design of a production system refers to the process
of planning and developing an efficient and effective
method of producing goods or services. It involves the
analysis of the production process, identification of the
required resources, and determination of the best way to
organize these resources to ensure that the production
process is efficient and cost-effective, which in turn leads
to increased profitability and customer satisfaction. It
involves several key steps including:
1. Determining the product or service to be produced:
The first step in designing a production system is to
identify the product or service that the organization
intends to produce. This involves analyzing the
market demand, identifying the customer
requirements, and determining the desired output.
2. Analyzing the production process: The next step is
to analyze the production process and identify the
various activities involved in producing the product
or service. This involves determining the sequence of
activities, the time required for each activity, and the
resources required.
3. Identifying the required resources: Once the
production process has been analyzed, the next step
is to identify the resources required to carry out the
process. This includes identifying the materials, labor,
equipment, and other resources required.
4. Determining the layout of the production system:
The layout of the production system is important for
ensuring that the resources are organized in the
most effective way possible. This involves
determining the location of the resources, the
sequence in which they will be used, and the flow of
materials and goods through the production process.
5. Determining the production capacity: The
production capacity of the system is determined by
analyzing the demand for the product or service and
the availability of resources. This involves
determining the number of products that can be
produced within a given time frame and the
resources required to achieve this level of production.
4.3 Types of production system
The two main types of production systems are:
 Intermittent Production System:
1. Project production flows
2. Jobbing production flows
3. Batch production flows
 Continuous Production System:
1. Mass production flows
2. Process production flows
4.4 Intermittent Production System
 Intermittent production system refers to a
manufacturing system in which the production of
goods is based on customer orders and the flow of
production is not continuous, but rather occurs in
irregular intervals. This system is characterized by
the production of a wide variety of products on a
small scale. The design of these products keeps
changing according to the customer's orders, making
the system very flexible.
 Some examples of intermittent production system
are the work of a goldsmith, who produces
ornaments on a small scale basis as per the
customer's requirements, and a tailor, who stitches
clothes for each customer independently as per
one's measurement and size. In this system, general-
purpose machines are used, and the sequence of
operation keeps changing as per the design of the
product.
 The characteristics or features of intermittent
production system are:
1. Production flow is not continuous but
intermittent
2. Wide variety of products are produced
3. Small volume of production
4. General-purpose machines are used
 5. Sequence of operation changes as per the design
of the product
6. The quantity, size, shape, design, etc. of the
product depends on the customer's orders.
 The three main types of intermittent production
systems are:
1. Project Production Flow: This type of production
system is used to manufacture products that are
unique and are only produced once. It involves a
large amount of planning and coordination, as
every project is different. Examples include
constructing a building, designing a new car
model, or producing a one-time special event.
2. Jobbing Production Flow: In this type of
production system, small quantities of products
are produced according to the customer's
requirements. This production system is
characterized by a high level of customization and
flexibility. For example, a carpenter who makes
custom furniture would use jobbing production
flow to produce unique pieces of furniture for
each customer.
3. Batch Production Flow: This type of production
system is used to manufacture products in small
batches. It involves producing a limited quantity
of products that are made to a specific design.
Examples include producing a limited quantity of
t-shirts with a specific design, or manufacturing a
batch of cookies with a particular recipe.
4.5 Continuous Production System
 A continuous production system is a type of
manufacturing system that operates constantly
without any interruptions or frequent halts. In this
system, goods are produced on a large scale for
stocking and selling, based on demand forecasts
rather than individual customer orders. The inputs
and outputs are standardized, and the production
process and sequence are predetermined.
 Examples of continuous production systems include
the food industry, where large-scale production of
food takes place based on demand forecasts, and the
fuel industry, where crude oil and other raw sources
are processed continuously on a large scale to yield
usable forms of fuel and meet global energy
demands.
 The characteristics or features of continuous
production system are:
1. Production is continuous, without any
interruptions
2. Products are always the same, following a
standard format
3. Quality is pre-determined and maintained
throughout production
4. Products are made in advance, based on
forecasted demand
5. Standardized schedules and instructions are used
for the production process.
 The two main types of continuous production
systems are:
1. Mass Production Flows: Mass production flows
involve the production of a large quantity of a
standardized product. The production process is
continuous, and the products are produced in
large volumes using specialized machinery. For
example, producing thousands of cars,
manufacturing a large quantity of pharmaceutical
products, or producing thousands of packaged
food items.
2. Process Production Flows: Process production
flows involve the production of a continuous flow
of a standardized product. The production
process is divided into a sequence of steps, and
each step is performed by specialized machinery.
For example, refining crude oil into petroleum
products, producing chemicals, or producing
electricity.
4.6 Production Planning & Control (PPC)
 PPC, or Production Planning and Control, is a process
used in manufacturing to ensure that products are
produced efficiently, on time, and at the desired
quality level. It involves the coordination of
resources, including people, machines, and materials,
to meet production goals while minimizing waste
and maximizing efficiency.
 Production planning is the process of determining
what products to produce, how much to produce,
and when to produce them. It involves creating a
production schedule, identifying necessary resources,
and setting production targets.
 Production control, on the other hand, is the process
of monitoring and controlling the production process
to ensure that it runs smoothly and according to plan.
This involves tracking production progress,
 identifying and resolving issues that arise, and
adjusting production plans as necessary.
 Together, production planning and control helps
manufacturers to optimize their resources, minimize
waste, and increase productivity, which ultimately
leads to higher profits.
 The main objectives of PPC are:
1. Meeting production targets
2. Optimizing utilization of resources
3. Ensuring timely delivery of products
4. Reducing production costs
5. Ensuring quality control
6. Minimizing production downtime
7. Enhancing customer satisfaction
8. Improving production efficiency
9. Facilitating continuous improvement
production processes.
5. Dispatching: The next step is dispatching, which
involves releasing the work orders to the shop floor.
The dispatching process involves providing the
necessary instructions to the operators, such as the
materials required, the sequence of operations, and
the production targets.
6. Follow up: Inspection and Correction: The final step
in the PPC process is follow up, which involves
monitoring the production process and making
corrections where necessary. Follow up involves
inspection of the work in progress to ensure that it
meets the quality standards, identifying any
deviations from the production plan, and taking
corrective actions to ensure that the production
targets are met.
in

4.7 Steps of PPC

The following are the six steps involved in the PPC
process:
1. Planning: The first step in PPC is planning, where the
production plan is formulated based on the sales
forecast and market demand. The production plan is
a document that outlines the quantity and type of
products that need to be produced within a specific
period. The plan takes into consideration the
production capacity, availability of resources, and
other factors that could impact production.
2. Routing: After the production plan is formulated, the
next step is routing. Routing involves determining
the sequence of operations that need to be
performed to produce a product. It also involves
determining the machines, tools, and equipment
required for each operation.
3. Scheduling: The third step is scheduling, which
involves creating a timetable for production. The
timetable outlines the start and end times for each
operation, taking into account the availability of
resources and the lead time required for each
operation.
4. Loading: After scheduling, the next step is loading.
Loading involves assigning the work to machines and
operators based on the production schedule. The
goal of loading is to ensure that the machines and
operators are utilized to their maximum capacity
while meeting the production targets.